Hulk Costume


New Member
I recently stumbled onto this site and really love all the Predator costumes everyone has made. I really want to buy a P1 kit from Termock (spelling?) next year. I've made some creative Halloween costumes over the years but nothing as elaborate as what many on here have done. My brothers talked me into making a Hulk Costume so we could be the Avengers for Halloween this year so I started on the build early last month. I am 60 hours into the build and wanted to share it with everyone here.

First off we wanted the hulk to be big but movable so we created Hulk Concept Drawings to show Hulks desired proportions and where a person would lie inside the suit, see diagram:

Now was the job of how to build it. We bought a bunch of couch foam from the craft store, a lycra suit, and couple cans of spray glue. I already had an electric carving knife from cutting custom slots in my rifle cases. I bought two rolls of duct tape and plastic wrap to make a mannequin of my body size.

The mannequin was the easy part, except we quickly discovered to put short strips on rather than having my wife wrap it around my arms, turning my hands purple. LOL

Then I took the diagrams and projected them onto the wall, we had to do some slight tweeks as we found that the proportions of the persons image we used was not the same as mine, I'm 6'2" 195 lbs so it made the Hulk slightly wider, we lined up the arm profiles with mine as well as the bottom of the feet the top of the head and the crotch. Once projected image on the wall matched my body proportions then my wife and I traced the outline of the hulk on wax paper and hung it on the wall for a side, front, and rear picture. Then I drew the muscles inside the outline freehand. Here are pic's of the wax paper drawings:

Now placing my dummy in lycra suit in front of the drawings, holding foam in hands and carving knife in the other I look at the drawing dumbfounded for a while trying to figure out how I'm going to attach shoulders that will be over 5" away from the dummies and a back that is over 10" from the dummies back. Finally we figured it out, we would cut truss's to Hulks Profile on the side and the back and then glue foam to the trusses. Now this was no easy task and took many many hours attaching each piece of foam, but one piece at the time we got each part figured out.


The chest, ribs and abs were easy, followed by the bicepts and shoulders, the tricepts were more difficult as the size became much larger and further away from the body and required multiple pieces of foam to be glued together. The back was very difficult as it required significant amounts of foam and several mounting pieces to secure the large pieces of foam to the lyrca suit and trusses. I basically carved each muscles shape with an electric carving knife to make it look realistic. It took some getting used to but it worked itself out.


Here you can see the upper body is nearly finished, I did eventually redo both front deltoids in the shoulders and one of the bicepts as well as the traps to improve the proportions. The forearms were worry-some because I had to glue approx 8" of foam to the rear and tie the front into the tricepts and bicepts. At first the forearms looked like giant drumsticks and but we carved some muscle definition and did some reshaping and they turned out great. We wanted the elbow to be able to bend but there would have to be a large section that would separate in order to do so, I was worried it would look dumb when the arm was bent but it doesn't it looks very natural.

My wife did the hands, she traced my hand profile and used 1" foam for the palms and 1/2" foam for the fingers. Initially she used 1" foam for both and the fingers and palms but it looked like mickey mouse hands so she redid the fingers. The hands in the left picture are 1/2" fingers and I believe the right picture is 1" fingers. The final hands have braces inside the palms separating the fingers and all three knuckles of each finger are slightly bent to look more natural. The hands allow about half of each of my fingers to insert into the fingers so I can move each individual finger (really cool looking! you will see in the video below).


Once we had the upper body done then I wanted to make sure we could get it off the mannequin so it was time for its first test fit. We unzipped the back and the dummy came right out, the lycra suit was still once piece and I was worried that if we left it as one piece it would be too bulky and stiff to climb into and get out of once the costume was complete.

The fitting went great, the upper body moves very easily and looks realistic. We were all extremely happy with how cool it turned out. My daughters had fun making fun of hulks big square butt (which we fixed later on) and they loved my skinny grey tights. LOL
Here is a video of the first test fitting:
After the First test fit my wife and I agreed it would be better to separate the top and bottom halves of the suit so we cut it in half, two inches below the waist line, to give us plenty of room to later attach velcro to join the two halves together keeping the seam inside of Hulks jeans.

In the concept drawings we wanted it to look like Hulk was hunched forward with legs bent while the wearer was standing upright which required large amounts of foam on the back, butt, front of the thighs, and on the rear calves. Sculpting the legs took about half as long as the top half. I should note that by this point we had gone back to the craft store for more foam and several more cans of spray glue. We had also worn out four electric carving knifes (dull blades and burned up motors).

The pictures show initial sculpting of first leg, it's still square and boxy and needs refinement, but the calf muscle has been built up to protrude approximately six to eight inches behind my actual calf, I believe the finished width of each calve ended up being 10.5". I made sure that the back of the knee was at the rear surface of the suit to allow for unrestricted bending of the knee.


In the mean time I found a decent latex mask online to go with the suit, funny thing is the mask is slightly smaller than the suit but still looks fine.

When carving the foam no matter what you do you will have jagged edges in the foam so to smooth out those edges we attached cloth with spray glue, the cloth did a much better job smoothing the surface than spandex and it made an excellent bonding surface for latex. Also when carving foam do not cut through foam that has wet spray glue on it, it gums up the knife blades and cuts poorly leaving very jagged edges.

Here the legs are pretty much finished and being test fitted. You can see the white cloth attached to the arms. When making muscle poses it looks like the muscles actually are flexing because they move so freely.


Here is a video of the fitting and no I do not normally dance to Alvin and the Chipmunks, but hey Costumes make people to crazy things. LOL

Now it was time for the feet. I hadn't been looking forward to the feet. I had been able to scrounge up some very hard foam that I had planned on carving the feet out of and using them as shoes. I started carving away and after an hour realized that the surface of the foam was too fragile and it was a terrible bonding surface. My son thought it was great to make a mess of when I had my back turned though. LOL


It was back to the drawing board on the feet. I knew I had to increase my height approx. 3" in order to keep the scale from our initial concept drawings. I scrounged through my closet and found a set of old boots that I hadn't worn in years and a pair of sandals with velcro straps that were at the end of their life. I decided to cut the rubber sole off of the boots and gorilla glue a 2x4 piece of wood between the sole and the bottom of the sandal. I cut the piece of wood the shape of the sole and spread glue onto every surface that I could I then tied the boot laces from the dismembered boots around the contraption. 24 hours later I removed the boot laces and I couldn't rip the sole or sandals off of the 2x4. I measured the thickness and it gave me 3.5" of additional height which was 1/2" more than my goal, I was excited. I then proceeded to attach the same couch foam around the perimeter of the new frankinstien shoes I just created. Using the same proportions off of the original concept drawings I carved out both feet and tested them out. The feet were very stable and worked great, I cut off the rear sandal strap so I could comfortably slide my foot in and out of the shoes easily.


After smoothing out the ankles on the feet and legs then I did my full test fit at which point my wife had wrapped nearly the entire suit with the cloth, as you can see it smoothed the muscles really well.

Here is a short video demonstrating walking around with the new feet, the suit now stands 6'7" tall, notice I nearly touch my head on the ceiling.

Time to do the Latex Paint, now this is my first experience with Latex so I had to do a bit of online research as well as some discussions with the local costume shops. I was going for a light olive drab like the version of Hulk in the new Avengers movie but the colorant I used in the latex has a demon soul. LOL I used a colorant powder for cosmetics that the local shop guy recommended but I found that as I brushed the coating more vigorously and then the green started coming out very bright and strong and the yellow seemed to fade.

I have two coats on most of the upper body, three on the feet, and one on the legs. I realize there are spots that got missed and I am going to go back over them after I get the main areas finished.

The green is very strong so I softened up the protruding areas of each muscle with a bit of yellow acrylic paint which helped a bunch but right now the color looks more like the cartoon hulk and I am going to try to tone it down more to get it where I want it by either entirely coating the suit again or by adding accents, shadows, highlights, etc... Whatever color scheme the body ends up being then I am going to paint the mask I bought to match the body. The latex has bonded great to the cloth and it looks and feels like real Hulk skin (at least how I would imagine it to be). Oh yeah almost forgot, I am still going to be adding veins and such. Also I have read that I need to put Talcum powder on the latex to get the stickiness to go away but it clouds the details, how do you guys get around this so your suits don't look like they just had a baby powder fart all over them?

Where this is my first latex experience I would really appreciate input and feedback.


In the picture showing the back then I put Talcum powder on the left foot to see what would happen.

that is def one of the better hulks i have seen. i would love to see some of your other elaborate costumes.
Totally awesome i dont know how people do this awesome stuff from foam, wow! Best hulk ive seen i must save the pics bro
Thanks guys I appreciate the positive comments! It has been great fun building the suit and definitely the hardest costume I have done to date.

Other costumes were like: Frankenstein, Dracula, zombie, etc and simple stuff for the kids.

Definitely could use some expert advice on the latex though so any help on coloration and talcum powder would be great.
You did an Amazingly Great job! You have a good eye for proportions, even when they are huge! I build my costumes the same way , with a spandex body suit and carved muscles on top. The cloth/ sprayglue is a superb idea for covering those "rough" edges over the muscles. To finish off painted latex, I prefer using PermaWet to seal it and give it a "wet" look. It also might help the stickyness factor.
Ok so who's going to be Thor and get punched out of scene then? Sorry if that's a spoiler ;-)
Amazing work mate can't wait to see it all complete well done !
The best colorant to use with latex is called pro line .. They are now being sold at Home Depot. If you plan on painting past the base latex color, mix what's called Pax. It's a combo if Acrylic paint, Prosaid adhesive and a bit of water. Powdering can be used with baby powder to reduce tackiness .. Then wipe off and you can seal it with Liquidex matte medium and water mixed. You can find the matte medium at most art supply stores
bad-ass man , me all kinds of ideas i can't afford at the moment,....hahah,.....( my son would LOVE this one )
phenomenal work and patience man ,......paid off well,...
Like it like it luv it..a great project mate..saw it first time last nite..had to see it again..well done for having the imagination and ingenuity to go for it..great job.
This thread is more than 5 years old.

Your message may be considered spam for the following reasons:

  1. This thread hasn't been active in some time. A new post in this thread might not contribute constructively to this discussion after so long.
If you wish to reply despite these issues, check the box below before replying.
Be aware that malicious compliance may result in more severe penalties.